Land Rover Defender: Fuel Filler Neck - Ingenium I4 2.0l Petrol

REMOVAL AND INSTALLATION

GENERAL EQUIPMENT

PART(S)

REMOVAL

WARNINGS:

• Wait for a minimum of 1 minute after the engine has stopped before carrying out any repair to the fuel injection system.
• Avoid flames, sparks or lighted substances.

CAUTION: Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTES:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.

1. Always follow the fuel system health and safety precautions when doing any repairs to the fuel system.

2. Use the Jaguar Land Rover (JLR) approved diagnostic equipment to depressurize the air suspension.

3. Drain the fuel tank.

4.

Open the fuel flap.

5.

Remove the fuel filler cap.

6. Raise and support the vehicle on a suitable 2-post lift.

7. Remove the right rear wheel arch liner.

8.

Release the evaporative emission canister hose.

9.

Release the breather hose from the 5 clips.

10.

Disconnect the electrical connector.

11.

Release the hose from the 4 clips.

12.

CAUTION: Care must be taken not to damage the body paint work.

• Release the for clips.
• Remove the fuel flap assembly.

13.

Release the air suspension hoses from the 3 clips at the right side.

14.

Release the air suspension hose from the 3 clips.

15.

Release the air suspension hose from the 2 clips at the left side.

16.

WARNING: Be prepared to collect escaping fuel.

• Remove the nut.
• Loosen the hose clamp and disconnect the fuel filler neck from the fuel tank.

17. Remove the rear driveshaft.

18.

NOTE: Repeat this step for the other side.

Remove and discard the nut and bolt.

19.

• Position the transmission jack below the rear subframe.

  General Equipment: Transmission jack

• Use a suitable wooden block to support the rear differential.

20.

NOTE: Repeat this step for the other side.

• Remove and discard the rear subframe bolt.
• Remove the support bracket bolt.
• Loosen the remaining support bracket bolt and reposition the bracket as illustrated.

21.

CAUTION: Make sure the rear subframe assembly is supported.

Use the transmission jack to lower the rear subframe front section carefully away from the vehicle.

22.

WARNING: Make sure the rear subframe assembly is adequately supported.

NOTE: Repeat this step for the other side.

• Measure the distance between point A and point B. The distance must not exceed 110mm.
• If the distance is greater than 110mm the transmission jack must be raised.

23.

WARNING: Make sure the rear subframe assembly is adequately supported.

NOTE: Repeat this step for the other side.

• Check the contact of the rear subframe rear section and the bush cups.
• If the contact has occurred the transmission jack must be raised.

24.

CAUTION: Care must be taken not to damage the body paint work.

• Remove the 2 nuts.
• Remove the bolt.
• Carefully remove the fuel filler neck from the vehicle.

INSTALLATION

1.

CAUTION: Care must be taken not to damage the body work.

• Install the fuel filler neck to the vehicle.
• Install and tighten the 2 nuts.

  Torque: 10Nm

• Install and tighten the bolt.

  Torque: 10Nm

2.

• Connect the fuel filler neck to the fuel tank.
• Install and tighten the nut.
• Torque: 10Nm
• Install and tighten the hose clamp.

  Torque: 3.2Nm

3.

CAUTIONS:

• Make sure that the components are correctly aligned.
• Only tighten the bolts finger tight at this stage.

• Use the transmission jack to raise the rear subframe front section carefully to the original position.
• Install, but do not fully tighten the rear subframe 4 new bolts.

  Renew Part: Rear subframe to body bolts Quantity: 4.

4.

Install the front subframe support bracket bolts.

Torque: 60Nm

5.

CAUTION: Only tighten the bolts finger tight at this stage.

NOTE: Repeat this step for the other side.

Install and hand tighten the new bolt and nut.

Renew Part: Shock absorber nut and bolt Quantity: 2.

6. Remove the transmission jack.

7. Install the rear driveshaft.

8.

Secure the air suspension hose to the 2 clips at the left side.

9.

Secure the air suspension hose to the 3 clips.

10.

Secure the air suspension hoses to the 3 clips at the right side.

11.

CAUTION: Make sure that all the clips are correctly installed.

Install the fuel filler assembly.

12.

Secure the hose to the 4 clips.

13.

Connect the electrical connector.

14.

Secure the breather hose at the 5 clips.

15.

Connect the evaporative emission canister hose.

16. Install the right rear wheel arch liner.

17.

Install the fuel filler cap.

18.

CAUTION: Nut and bolt must be tightened with vehicle at normal ride height.

NOTE: Repeat this step for the other side.

Install and tighten the new bolt and nut.

Renew Part: Shock absorber nut and bolt Quantity: 2.

Torque

• Stage1: 100Nm
• Stage2: 240º

19.

CAUTION: Bolts must be tightened with vehicle at normal ride height.

Fully tighten the 4 new subframe bolts.

Torque

Front bolts

• Stage1: 100Nm
• Stage2: 240º

Rear bolts

• Stage1: 100Nm
• Stage2: 300º

20.

WARNING: After doing repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in personal injury.

Fill the fuel tank with the amount recovered during the fuel tank drain procedure.

21. Use the Jaguar Land Rover (JLR) approved diagnostic equipment to pressurize the air suspension.

22. Use the Jaguar Land Rover (JLR) approved diagnostic equipment to check and if necessary adjust the wheel alignment.

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